ES3036254T3 - User initiated break-away clutching of a surgical mounting platform - Google Patents

Abstract

Robotic and/or surgical devices, systems, and methods include kinematic joint structures and associated control systems configured to facilitate preparation of the system for use. One or more kinematic joint subsystems may include active, passive, or a combination of both actuated joints. The configuration mode employs an intuitive user interface in which one or more joints are initially held static by a brake or joint actuation system. The user may articulate the joint(s) by manually pressing against the joint with a force, torque, or the like that exceeds a manual articulation threshold. Articulation of movable joints is facilitated by modifying signals transmitted to the brake or actuation system. The system may detect completion of reconfiguration when the velocity of the joint(s) drops below a threshold, optionally for a desired dwell time. The system may provide manual detent-like articulation, which is not limited to mechanically predefined detent joint configurations. Embodiments of the invention provide, and may be particularly suitable for, manual movement of a platform supporting a plurality of surgical manipulators in a robotic or similar surgical system without the need for additional input devices. (Automatic translation with Google Translate, no legal value)

Description

DESCRIPTION

User-initiated detachment clutch of a surgical mounting platform BACKGROUND

[0001] Minimally invasive medical techniques aim to reduce the amount of foreign tissue damaged during diagnostic or surgical procedures, thereby reducing patient recovery time, discomfort, and harmful side effects. One effect of minimally invasive surgery, for example, is the reduction of postoperative hospital recovery times. Because the average hospital stay for standard surgery is typically significantly longer than the average stay for a similar minimally invasive surgery, greater use of minimally invasive techniques could save millions of dollars in hospital costs each year. While many of the surgeries performed each year in the United States could potentially be performed in a minimally invasive manner, only a portion of current surgeries utilize these advantageous techniques due to limitations in minimally invasive surgical instruments and the additional surgical training involved in mastering them.

[0002] Minimally invasive robotic surgical or telesurgical systems have been developed to augment a surgeon's dexterity and overcome some of the limitations of traditional minimally invasive techniques. In telesurgery, the surgeon uses some form of remote control (e.g., a servomechanism or similar) to manipulate the movements of the surgical instrument, rather than directly holding and moving the instruments by hand. In telesurgery systems, the surgeon can obtain an image of the surgical site on a surgical workstation. While viewing a two-dimensional or three-dimensional image of the surgical site on a screen, the surgeon performs the surgical procedures on the patient by manipulating master control devices, which in turn control the movement of the servomechanically operated instruments.

[0003] The servomechanism used for telesurgery will often accept input from two master controllers (one for each of the surgeon's hands) and may include two or more robotic arms, each of which is mounted with a surgical instrument. Operational communication between the master controllers and the associated robotic arm and instrument assemblies is typically achieved through a control system. The control system typically includes at least one processor that transmits input commands from the master controllers to the associated robotic arm and instrument assemblies and vice versa (back from the arm and instrument assemblies to the associated master controllers) in the case of, for example, force feedback or similar input. An example of a robotic surgical system is the DA VINCI® system available from Intuitive Surgical, Inc. of Sunnyvale, California.

[0004] A variety of structural arrangements can be used to support the surgical instrument at the surgical site during robotic surgery. The driven or "slave" linkage is often referred to as the robotic surgical manipulator, and exemplary linkage arrangements for use as a robotic surgical manipulator during minimally invasive robotic surgery are described in U.S. Patent Nos. 7,594,912; 6,758,843; 6,246,200; and 5,800,423. These linkages often make use of a parallelogram arrangement to support an instrument having a shaft. Such a manipulator structure can restrict the movement of the instrument so that the instrument pivots about a remote center of manipulation positioned in space along the length of the rigid shaft. By aligning the remote manipulation center with the incision point at the internal surgical site (e.g., with a trocar or cannula in an abdominal wall during laparoscopic surgery), a surgical instrument end effector can be safely positioned by moving the proximal end of the shaft using the manipulator linkage without imposing potentially hazardous forces against the abdominal wall. Alternative manipulator structures are described, for example, in U.S. Patent Nos. 7,763,015; 6,702,805; 6,676,669; 5,855,583; 5,808,665; 5,445,166; and 5,184,601.

[0005] A variety of structural arrangements can also be used to support and position the robotic surgical manipulator and surgical instrument at the surgical site during robotic surgery. Support linkage mechanisms, sometimes called setup joints or setup joint arms, are often used to position and align each manipulator with the respective incision point on a patient's body. The support linkage mechanism facilitates the alignment of a surgical manipulator with a desired surgical incision point and target anatomy. Exemplary support linkage mechanisms are described in U.S. Patents 6,246,200 and 6,788,018.

[0006] While new telesurgical systems and devices have proven to be highly effective and advantageous, further improvements are still desirable. In general, improved minimally invasive robotic surgery systems are desired. It would be particularly beneficial if these improved technologies enhanced the efficiency and ease of use of robotic surgical systems. For example, it would be particularly beneficial to increase maneuverability, improve space utilization in an operating room, provide faster and easier setup, inhibit collisions between robotic devices during use, and/or reduce the mechanical complexity and size of these new surgical systems.

[0007] WO 2006/124390 describes a software hub and a highly configurable robotic system for surgery and other uses. In some embodiments, the configurable robotic system includes a clutch mode where the user can manually articulate the manipulator assembly by applying forces exceeding the haptic threshold against appropriate structures of the manipulator assembly. The configurable robotic system remains in clutch mode until the external articulation forces fall below a threshold value.

[0008] US patent 2010/0234857 describes a medical robotic system with an operationally attachable simulator unit for training surgeons. The medical robotic system includes controllers or control modules to compensate for friction and gravity. The medical robotic system also includes a slave clutch button which, when pressed, interrupts the control loop so that the robotic arms can float relative to the master controls used to manipulate the robotic arms.

[0009] US Patent 2010/0161129 relates to a system and procedure for adjusting an image capture device attribute using an unused degree of freedom of a master control device. The system and procedure include determining whether the master controls are positioning or orienting the image capture device before adjusting the attribute of the image capture device. The system and procedure further determine whether the master controls are positioning or orienting the image capture device by determining whether the speed of the image capture device or the master controls is above a threshold speed.

BRIEF SUMMARY

[0010] The present invention provides an unclaimed method for configuring a robotic system and a robotic system as set forth in the appended claims. A simplified summary of some embodiments of the invention is presented below to provide a basic understanding of the invention. This summary is not a comprehensive overview of the invention. It is not intended to identify key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some embodiments of the invention in a simplified manner as a prelude to the more detailed description presented later.

[0011] The present description generally provides improved robotic and/or surgical devices, systems, and procedures. The kinematic linkage structures and associated control systems described in this invention are particularly beneficial in assisting system users to position the robotic structure in preparation for use, including in preparation for a surgical procedure on a particular patient. The exemplary robotic surgical systems described in this invention may have one or more kinematic linkage subsystems configured to assist in aligning a manipulator structure with the surgical work site. The joints of these configuration systems may be actively actuated, passively actuated (so that they are manually articulated and then locked in the desired configuration while the manipulator is used therapeutically), or a combination of both. Embodiments of the robotic systems described in this invention may employ a configuration mode where one or more joints are initially held static by a braking or joint-actuating system. Inadvertent articulation is limited by the brake or drive system, but the user can manually articulate the joint(s) by manually pushing against the linkage with a force, torque, or similar that exceeds a manual articulation threshold for the joint(s). Once the joint(s) begin to move, a processor can facilitate articulation with less user effort by modifying the signals transmitted to the brake or drive system. When the user reaches a desired configuration, the system can detect that the user has completed the reconfiguration from a joint(s) speed below a threshold, optionally for a desired dwell time. The system can then inhibit inadvertent articulation of the joint(s). The dwell time can help prevent linkage locking when directions are reversed, and the system can provide a manual "detent"-like articulation that is not limited to mechanically predefined detent joint configurations. The embodiments of the invention provide a user interface that is intuitive, and may be particularly suitable for the manual movement of a platform supporting a plurality of surgical manipulators in a robotic surgical system or the like without having to add additional input devices.

[0012] In one aspect, the description provides a procedure for configuring a robotic system. The procedure comprises inhibiting the manual articulation of a system link from a first pose in response to a first manual effort against the link that is below a desired articulation threshold. Manual movement of the link from the first pose to a second pose is facilitated in response to a second manual effort to articulate the link that exceeds the desired articulation threshold. The second pose is determined in response to the determination that a manual movement speed is below a threshold speed. Manual movement of the link is inhibited from the second pose.

[0013] Therefore, in the first aspect, a procedure for configuring a robotic system is provided. The procedure includes inhibiting the manual articulation of a system link from a first pose in response to a first manual effort against the link, facilitating a manual movement of the link from the first pose to a second pose, determining the second pose in response to the determination that a manual movement speed is below a threshold speed, and inhibiting the manual movement of the link from the second pose. The inhibition step is in response to a first manual effort against the link that is below a desired articulation threshold. The facilitation step is in response to a second manual effort against the link that exceeds the desired articulation threshold.

[0014] In other exemplary embodiments, a joint sensor can detect a first torque from the first manual effort applied to a joint, and a processor can inhibit manual joint movement by determining drive signals configured to induce a counter-torque at the linkage that opposes the first torque, thus driving the linkage back into the first pose. In further embodiments, the joint sensor can also detect the second torque from the second manual effort applied to the joint, and the processor can be configured to determine that the second effort exceeds the desired joint threshold. For example, in some embodiments, the joint threshold can be a torque threshold, and the processor can determine that the second effort exceeds the desired joint threshold by determining that the second torque exceeds the threshold torque. In response to a second effort exceeding the desired joint threshold, the processor can alter the drive signals to decrease the counter-torque, so that the first torque is sufficient to manually move the manipulator.

[0015] In some embodiments of the procedure, a processor can alter the drive signals in response to the second effort exceeding the desired articulation threshold by adding a friction compensation component to the drive signals to mitigate linkage friction for manual movement into the second pose.

[0016] In other embodiments, the second pose can be determined by establishing that the speed of the manual movement is below a threshold speed. Furthermore, the second pose can also be determined by establishing that the speed of the manual movement remains below the threshold speed for a threshold dwell time to facilitate reversing a direction of movement without inhibiting the manual movement.

[0017] In further embodiments, the procedure for setting up a robotic system includes actuating the linkage in the second pose with actuation signals to inhibit manual movement of the linkage from the second pose in response to a third manual effort against the manipulator that is below the desired articulation threshold.

[0018] The preceding exemplary procedures can be used to configure a surgical robotic system. For example, the linkage can be a configuration structure having a proximal base and a platform with the joint disposed between them. The platform can support a plurality of surgical manipulators, where each manipulator can be an instrument holder configured to releasably receive a surgical instrument. The manual movement can be a movement that alters the positions of the plurality of manipulators with respect to a surgical site. In another example, the linkage can be included in a surgical manipulator having a holder to releasably receive a surgical instrument. The surgical manipulator can also include a cannula interface configured to releasably receive a cannula. The manipulator can further be configured to pivot an instrument shaft within an opening adjacent to the cannula to manipulate an end effector of the instrument within a minimally invasive surgical opening. The setup procedure may also include inhibiting manual articulation of the joint with a manual effort that exceeds the desired articulation threshold in response to mounting the cannula on the cannula interface.

[0019] In another aspect, a robotic system is provided. The robotic system includes a linkage having an articulation, a drive or brake system coupled to the linkage, and a processor coupled with the drive or brake system. The processor can be configured to transmit signals to the drive or brake system to inhibit manual articulation of the linkage from a first pose in response to a first manual effort against the linkage that is below a desired articulation threshold. The processor can alter the signals in response to a second manual effort to articulate the linkage that exceeds the desired articulation threshold. The altered signals can be configured to facilitate manual movement of the linkage from the first pose to a second pose. The processor can also determine the second pose in response to the detection that a manual movement speed is below a first threshold speed and can transmit signals to the drive system to inhibit manual movement of the linkage from the second pose.

[0020] In further exemplary embodiments, the robotic system further includes a joint sensor coupled to the joint. The joint sensor can be configured to detect a first torque from the first manual effort applied to the joint. The processor can be configured to determine the signals in order to apply a counter-torque to the linkage that opposes the first torque and drives the linkage back into the first pose. In particular embodiments, a drive or brake system may include a drive system. In addition, the joint sensor can be configured to transmit to the processor a second torque from the second manual effort applied to the joint. The processor can further be configured to determine whether the second effort exceeds the desired joint threshold using the second torque. For example, the processor can be configured to determine that the second effort exceeds the desired joint threshold by determining whether the second torque exceeds a threshold torque. In response to a second effort exceeding the desired joint threshold, the processor can alter the drive signals to decrease the counter-torque, so that the first torque is sufficient to manually move the manipulator.

[0021] In some embodiments, the robotic system signals may include drive signals and the processor may be configured to alter the drive signals in response to the second effort exceeding the desired articulation threshold by adding a friction compensation component to the drive signals to mitigate linkage friction for manual movement into the second pose.

[0022] The processor can be configured to determine a second pose in response to a hand movement speed below a threshold speed. The processor can also be configured to determine the second pose by determining that the hand movement speed is below the threshold speed for a threshold dwell time to facilitate a reversal of a hand movement direction without inhibiting the hand movement. The processor can also be configured to inhibit the linkage hand movement from the second pose in response to a third hand effort against the manipulator that is below the desired articulation threshold.

[0023] The above exemplary system may be a surgical robotic system. For example, the linkage may be a configuration structure having a proximal base and a platform with the joint disposed between them. The platform may support a plurality of surgical manipulators, where each manipulator may be an instrument holder configured to releasably receive a surgical instrument. The manual movement may be a movement that alters the positions of the plurality of manipulators with respect to a surgical site. In another example, the linkage may be included in a surgical manipulator having a holder to releasably receive a surgical instrument. The surgical manipulator may also include a cannula interface configured to releasably receive a cannula. The manipulator may further be configured to pivot an instrument shaft within an opening adjacent to the cannula to manipulate an end effector of the instrument within a minimally invasive surgical opening. The system may also include inhibiting manual articulation of the joint with a manual effort that exceeds the desired articulation threshold in response to mounting the cannula on the cannula interface.

[0024] In one embodiment, a robotic surgical system is provided. The robotic surgical system includes a linkage having a joint, a torque sensor system coupled to the joint, and a processor that couples the torque sensor to the drive system. The joint can be arranged between a proximal base and an instrument holder. The instrument holder can be configured to releasably support a surgical instrument. The processor is configured to transmit drive signals to the drive system to inhibit manual articulation of the joint from a first configuration in response to a detected torque that is below a desired articulation threshold. In response to a detected torque that exceeds the desired articulation threshold, the processor can alter the drive signals to facilitate manual movement of the joint from the first configuration to a second configuration using a movement torque below the articulation threshold. In response to a manual movement speed falling below a threshold speed, the processor can determine the second configuration. The processor can also be configured to transmit drive signals to the drive system to inhibit manual linkage movement from the second pose in response to a detected torque that is below a desired articulation threshold.

[0025] A procedure for setting up a robotic system is also described. The procedure includes actuating a robotic assembly during manual efforts to move a link of the assembly to simulate a first and second link detent in the first and second link poses. The procedure also includes determining the second pose in response to a manual movement of the link to the second pose.

[0026] For a more complete understanding of the nature and advantages of the present invention, reference should be made to the following detailed description and accompanying drawings. Other aspects, objects, and advantages of the invention will be apparent from the drawings and the detailed description that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027]

FIG. 1 is a plan view of a minimally invasive robotic surgery system used to perform surgery, according to various realizations.

FIG. 2 is a perspective view of a surgeon's control console for a robotic surgery system, according to various embodiments.

FIG. 3 is a perspective view of an electronic cart of a robotic surgery system, according to various embodiments.

FIG.4 schematically illustrates a robotic surgery system, according to various implementations.

FIG.5A is a partial view of a patient-side cart (surgical robot) of a robotic surgery system, according to various embodiments.

FIG. 5B is a front view of a robotic surgery tool, according to various embodiments.

FIG. 6 is a schematic perspective representation of a robotic surgery system, according to various realizations.

FIG. 7 is a schematic perspective representation of another robotic surgery system, according to various realizations.

FIG.8 shows a robotic surgery system, according to various embodiments, in accordance with the schematic representation of FIG.7.

FIG.9 illustrates the rotational orientation limits of the configuration links with respect to an orientation platform of the robotic surgery system of FIG.8.

FIG. 10 shows a diagram of the center of gravity associated with a rotation limit of the arm assembly for a robotic surgery system, according to various embodiments.

FIG. 11 is a flowchart that schematically illustrates a procedure for preparing a robotic surgical system for surgery.

DETAILED DESCRIPTION

[0028] The following description will describe various embodiments of the present invention. For explanatory purposes, specific configurations and details are set forth to provide a complete understanding of the embodiments. However, it will be evident to a person skilled in the art that the present invention can be implemented without these specific details. Furthermore, well-known features may be omitted or simplified so as not to obscure the embodiment being described.

[0029] The kinematic linkage structures and control systems described in this invention are particularly beneficial in assisting system users to organize the robotic structure for a procedure on a particular patient. Along with the actively driven manipulators used to interact with tissues and the like during treatment, robotic surgical systems may have one or more kinematic linkage systems configured to support and assist in aligning the manipulator structure with the surgical work site. These configuration systems may be actively driven or passive, such that they are manually articulated and then locked in the desired configuration while the manipulator is being used therapeutically. Passive configuration kinematic systems may have advantages in terms of size, weight, complexity, and cost. Unfortunately, multiple manipulators may be used to treat each patient's tissues. Each manipulator can independently benefit from precise positioning to allow the instrument it supports to have the desired movement throughout the workspace, and minor changes in the relative locations of adjacent manipulators can significantly impact interactions between them (with mispositioned manipulators potentially colliding or having their reach and/or ease of movement significantly reduced). Therefore, the challenges of rapidly organizing the robotic system in preparation for surgery can be significant.

[0030] One option is to mount multiple manipulators on a single platform, sometimes referred to as the manipulator support platform or orientation platform. The orientation platform may be supported by an actively driven support linkage (sometimes referred to in this invention as the setup structure, and which typically has a setup structure linkage, etc.). The system may also provide and control motorized axes of the robotic setup structure supporting the orientation platform with some type of joystick or set of buttons that would allow the user to actively actuate those axes independently as desired. This strategy, while useful in some situations, may present some disadvantages. In particular, it may be difficult to locate a single actuation button for all elements of a complex system so that each is accessible to users approaching the system in all its potential configurations. While individual clutch buttons may also be used to release the brake or drive system, there may be a possibility of confusion between buttons that have different functions. Furthermore, both sterile and non-sterile elements of a surgical team may need to articulate certain joints or links (for example, by grasping different locations within or outside the sterile field). Therefore, a more intuitive and flexible user interface would be desirable. This is particularly true for a guidance platform for use in multi-quadrant surgery, or for a structure that supports multiple surgical manipulators and can pivot around an axis that extends at least approximately vertically to orient the manipulators relative to a patient on a surgical table or other support.

Minimally invasive robotic surgery

[0031] With reference now to the drawings, where similar reference numbers represent similar parts throughout the various views, FIG. 1 is a plan view illustration of a Minimally Invasive Robotic Surgical (MIRS) system 10, typically used to perform a minimally invasive surgical or diagnostic procedure on a patient 12 lying on an operating table 14. The system may include a surgeon's console 16 for use by a surgeon 18 during the procedure. One or more assistants 20 may also participate in the procedure. The MIRS 10 system may further include a patient-side cart 22 (surgical robot) and an electronic cart 24. The patient-side cart 22 can manipulate at least one detachable tool set 26 (hereafter referred to simply as a "tool") through a minimally invasive incision in the patient's body 12 while the surgeon 18 views the surgical site via the console 16. An image of the surgical site can be obtained using an endoscope 28, such as a stereoscopic endoscope, which can manipulate the patient-side cart 22 to orient the endoscope 28. The electronic cart 24 can be used to process the images of the surgical site for subsequent viewing by the surgeon 18 via the surgeon's console 16. The number of surgical tools 26 used at one time will generally depend on the diagnostic or surgical procedure and space limitations within the operating room, among other factors. If it is necessary to change one or more of the tools 26 used during a procedure, an assistant 20 can remove the tool 26 from the patient-side cart 22 and replace it with another tool 26 from a tray 30 in the operating room.

[0032] FIG. 2 is a perspective view of the surgeon's console 16. The surgeon's console 16 includes a left-eye display 32 and a right-eye display 34 to present the surgeon 18 with a coordinated stereo view of the surgical site that allows for depth perception. The console 16 further includes one or more input control devices 36, which in turn make the patient-side cart 22 (shown in FIG.

1) Manipulate one or more tools. Input control devices 36 can provide the same degrees of freedom as their associated tools 26 (shown in FIG. 1) to provide the surgeon with telepresence, or the perception that the input control devices 36 are an integral part of the tools 26, so that the surgeon has a strong sense of direct control of the tools 26. To this end, position, force, and tactile feedback sensors (not shown) can be employed to transmit position, force, and tactile sensations from the tools 26 back to the surgeon's hands via the input control devices 36.

[0033] The surgeon's console 16 is generally located in the same room as the patient so that the surgeon can directly monitor the procedure, be physically present if necessary, and speak with an assistant directly rather than by telephone or other means of communication. However, the surgeon may be located in a different room, a completely different building, or another location remote from the patient, enabling remote surgical procedures.

[0034] Figure 3 is a perspective view of the electronic cart 24. The electronic cart 24 can be attached to the endoscope 28 and may include a processor for processing the captured images for later viewing, such as to a surgeon on the surgeon's console, or on another suitable display located locally and/or remotely. For example, when using a stereoscopic endoscope, the electronic cart 24 can process the captured images to present the surgeon with coordinated stereo images of the surgical site. Such coordination may include aligning the opposing images and adjusting the stereo working distance of the stereoscopic endoscope. As another example, image processing may include using predetermined camera calibration parameters to compensate for image errors from the image capture device, such as optical aberrations.

[0035] Figure 4 schematically illustrates a robotic surgery system 50 (such as the MIRS system 10 in Figure 1). As discussed earlier, a surgeon can use a surgeon's console 52 (such as surgeon's console 16 in Figure 1) to control a patient-side cart (surgical robot) 54 (such as patient-side cart 22 in Figure 1) during a minimally invasive procedure. The patient-side cart 54 can use an imaging device, such as a stereoscopic endoscope, to capture images of the procedure site and output the captured images to an electronic cart 56 (such as electronic cart 24 in Figure 1). As discussed earlier, the electronic cart 56 can process the captured images in various ways before any further viewing. For example, the electronic cart 56 can overlay captured images with a virtual control interface before displaying the combined images to the surgeon via the surgeon's console 52. The patient-side cart 54 can output captured images for processing outside of the electronic cart 56. For example, the patient-side cart 54 can output captured images to a processor 58, which can be used to process the captured images. Images can also be processed by a combination of the electronic cart 56 and the processor 58, which can be coupled together to process captured images jointly, sequentially, and/or combinations thereof. One or more separate displays 60 can also be coupled with the processor 58 and/or the electronic cart 56 for local and/or remote image viewing, such as images of the procedure site or other related images.

[0036] The 58 processor will typically include a combination of hardware and software, the software comprising tangible media incorporating computer-readable code instructions for performing the control procedure steps functionally described in this invention. The hardware typically includes one or more data processing boards, which may be located together, but will often have components distributed among the robotic structures described in this invention. The software will often comprise a non-volatile medium, and could also comprise monolithic code, but more typically will comprise a series of subroutines, optionally running on any of a wide variety of distributed data processing architectures.

[0037] Figures 5A and 5B show a patient-side cart 22 and a surgical tool 62, respectively. Surgical tool 62 is an example of surgical tools 26. The patient-side cart 22 shown provides manipulation of three surgical tools 26 and an imaging device 28, such as a stereoscopic endoscope used for capturing images of the procedure site. Manipulation is provided by robotic mechanisms having a series of robotic joints. The imaging device 28 and the surgical tools 26 can be positioned and manipulated through incisions in the patient so that a remote kinematic center is maintained at the incision to minimize the incision size. Surgical site images can include images of the distal ends of the surgical tools 26 when they are placed within the field of view of the imaging device 28.

[0038] Surgical tools 26 are inserted into the patient by inserting a tubular cannula 64 through a minimally invasive access opening, such as an incision, natural orifice, percutaneous penetration, or similar. The cannula 64 is mounted on the robotic manipulator arm, and the shaft of the surgical tool 26 passes through the cannula's lumen. The manipulator arm can transmit signals indicating that the cannula has been mounted on it.

Robotic surgery systems and modular manipulator supports

[0039] FIG. 6 is a schematic perspective representation of a robotic surgery system 70, according to various embodiments. The surgery system 70 includes a mounting base 72, a support link 74, an orientation platform 76, a plurality of external configuration links 78 (two are shown), a plurality of internal configuration links 80 (two are shown), and a plurality of surgical instrument manipulators 82. Each of the manipulators 82 can function to selectively articulate a surgical instrument mounted on the manipulator 82 and insertable into a patient along an insertion axis. Each of the manipulators 82 is attached to and supported by one of the configuration links 78, 80. Each of the external configuration links 78 is rotatably coupled and supported by the orientation platform 76 via a first configuration link joint 84. Each of the internal configuration links 80 is fixedly attached to and supported by the orientation platform 76. The orientation platform 76 is rotatably coupled to and supported by the support link 74. And the support link 74 is fixedly attached to and supported by the mounting base 72.

[0040] In several embodiments, the mounting base 72 is mobile and supported on the floor, allowing selective repositioning of the general surgery system 70, for example, within an operating room. The mounting base 72 may include a swivel caster assembly and/or any other suitable support feature that provides selective repositioning and selectively prevents movement of the mounting base 72 from a selected position. The mounting base 72 may also have other suitable configurations, for example, a ceiling mount, a fixed floor/pedestal mount, a wall mount, or an interface configured to be supported by any other suitable mounting surface.

[0041] The support link 74 is operable to selectively position and/or orient the orientation platform 76 with respect to the mounting base 72. The support link 74 includes a column base 86, a movable column element 88, a shoulder joint 90, an arm base element 92, a first-stage arm element 94, a second-stage arm element 96, and a wrist joint 98. The column base 86 is fixedly attached to the mounting base 72. The movable column element 88 is slidably coupled to the column base 86 for translation with respect to the column base 86. In several embodiments, the movable column element 88 is translated with respect to the column base 86 along a vertically oriented axis. The arm base element 92 is rotatably coupled to the movable column element 88 by the shoulder joint 90. The shoulder joint 90 is operable to selectively orient the arm base element 92 in a horizontal plane with respect to the movable column element 88, which has a fixed angular orientation with respect to the column base 86 and the mounting base 72. The first arm stage element 94 can be selectively translated with respect to the arm base element 92 in a horizontal direction, which in several embodiments is aligned with both the arm base element 92 and the first arm stage element 94. The second arm stage element 96 is likewise selectively translated with respect to the first arm stage element 94 in a horizontal direction, which in several embodiments is aligned with both the first arm stage element 94 and the second arm stage element 96. Consequently, the support link 74 is operable to selectively set the distance between the shoulder joint 90 and the distal end of the second-stage arm element 96. The wrist joint 98 rotatably couples the distal end of the second-stage arm element 96 to the orientation platform 76. The wrist joint 98 is operable to selectively set the angular orientation of the orientation platform 76 with respect to the mounting base 72.

[0042] Each of the configuration links 78, 80 is operable to selectively position and/or orient the associated manipulator 82 with respect to the orientation platform 76. Each of the configuration links 78, 80 includes a base link of configuration link 100, an extension link of configuration link 102, a parallelogram link portion of configuration link 104, a vertical link of configuration link 106, a second joint of configuration link 108, and a manipulator support link 110. Each of the base links of configuration link 100 of the outer configuration links 78 can be selectively oriented with respect to the orientation platform 76 by operating a first joint of configuration link 84. In the embodiment shown, each of the base links of configuration link 100 of the inner configuration links 80 is fixedly attached to the orientation platform 76. Each One of the internal configuration links 80 can also be rotatably attached to the orientation platform 76 in a manner similar to the external configuration links via an additional first configuration link joint 84. Each of the configuration link extension links 102 can be translated with respect to the associated configuration link base link 100 in a horizontal direction, which in various embodiments is aligned with the associated configuration link base link and the configuration link extension link 102. Each of the configuration link parallelogram parts 104 is configured and operable to selectively translate the configuration link vertical link 106 in a vertical direction while maintaining the configuration link vertical link 106 vertically oriented. In example embodiments, each of the configured parallelogram link parts 104 includes a first parallelogram joint 112, a coupling link 114, and a second parallelogram 116. The first parallelogram joint 112 rotatably couples the coupling link 114 to the extension link of configuration link 102. The second parallelogram joint 116 rotatably couples the vertical link of configuration link 106 to the coupling link 114. The first parallelogram joint 112 is rotatably connected to the second parallelogram joint 116 such that the rotation of the coupling link 114 with respect to the extension link of configuration link 102 coincides with a counter-rotation of the vertical link of configuration link 106 with respect to the coupling link 114, to maintain the vertical link of configuration link 106 vertically oriented while said vertical link of configuration link 106 is translated selectively vertically. The second configuration link joint 108 is operable to selectively orient the manipulator support link 110 with respect to the vertical link of configuration link 106, thereby selectively orienting the associated attached manipulator 82 with respect to the vertical link of configuration link 106.

[0043] Figure 7 is a schematic perspective representation of a robotic surgical system 120, according to various embodiments. Because the surgical system 120 includes components similar to the components of the surgical system 70 in Figure 6, the same part numbers are used for similar components, and the corresponding description of similar components established above is applicable to the surgical system 120 and is omitted here to avoid repetition. The surgical system 120 includes the mounting base 72, a support link 122, a guidance platform 124, a plurality of configuration links 126 (four are shown), and a plurality of surgical instrument manipulators 82. Each of the manipulators 82 can function to selectively articulate a surgical instrument mounted on the manipulator 82 and insertable into a patient along an insertion axis. Each of the manipulators 82 is attached to and supported by one of the configuration links 126. Each of the configuration links 126 is rotatably coupled and supported by the orientation platform 124 via the first configuration link joint 84. The orientation platform 124 is rotatably coupled and supported by the support link 122. And the support link 122 is fixedly attached to and supported by the mounting base 72.

[0044] The support link 122 is operable to selectively position and/or orient the orientation platform 124 with respect to the mounting base 72. The support link 122 includes the column base 86, the movable column element 88, the shoulder joint 90, the arm base element 92, the first-stage arm element 94, and the wrist joint 98. The support link 122 can be operated to selectively set the distance between the shoulder joint 90 and the distal end of the first-stage arm element 94. The wrist joint 98 rotatably couples the distal end of the first-stage arm element 94 to the orientation platform 124. The wrist joint 98 is operable to selectively set the angular orientation of the orientation platform 124 with respect to the mounting base 72.

[0045] Each of the configuration links 126 can be operated to selectively position and/or orient the associated manipulator 82 with respect to the orientation platform 124. Each of the configuration links 126 includes the base link of configuration link 100, the extension link of configuration link 102, the vertical link of configuration link 106, the second configuration link joint 108, a support link of the tornado mechanism 128, and a tornado mechanism 130. Each of the base links of configuration link 100 of the configuration links 126 can be selectively oriented with respect to the orientation platform 124 by operating the associated first configuration link joint 84. Each of the vertical configuration link links 106 can be selectively moved in a vertical direction with respect to the associated configuration link extension link 102. The second configuration link joint 108 is operable to selectively orient the tornado mechanism support link 128 with respect to the vertical configuration link link 106.

[0046] Each of the tornado mechanisms 130 includes a tornado joint 132, a coupling link 134, and a manipulator support 136. The coupling link 134 permanently couples the manipulator support 136 to the tornado joint 132. The tornado joint 130 can be operated to rotate the manipulator support 136 with respect to the support link of the tornado mechanism 128 about a tornado axis 136. The tornado mechanism 128 is configured to position and orient the manipulator support 134 so that the remote manipulation center (RC) of the manipulator 82 is intersected by the tornado axis 136. Consequently, the operation of the tornado joint 132 can be used to reorient the associated manipulator 82 with respect to the patient without moving the associated remote manipulation center (RC) with respect to the patient.

[0047] FIG. 8 is a simplified representation of a robotic surgery system 140, according to various embodiments, in accordance with the schematic representation of the robotic surgery system 120 in FIG. 7. Because the surgery system 140 conforms to the robotic surgery system 120 of FIG. 7, the same part numbers are used for analogous components and the corresponding description of the analogous components set out above is applicable to the surgery system 140 and is omitted here to avoid repetition.

[0048] The support link 122 is configured to selectively position and orient the orientation platform 124 with respect to the mounting base 72 through relative movement between the links of the support link 122 along multiple setup structure axes. The movable column element 88 can be selectively repositioned with respect to the column base 86 along a first setup structure (SUS) axis 142, which is vertically oriented in various embodiments. The shoulder joint 90 is operable to selectively orient the arm base element 92 with respect to the movable column element 88 around a second SUS axis 144, which is vertically oriented in various embodiments. The first arm stage element 94 can be selectively repositioned with respect to the arm base element 92 along a third SUS axis 146, which is horizontally oriented in various embodiments. The wrist joint 98 is operable to selectively orient the orientation platform 124 with respect to the first stage arm element 94 around a fourth SUS axis 148, which is vertically oriented in various embodiments.

[0049] Each of the configuration linkages 126 is configured to selectively position and orient the associated manipulator 82 with respect to the orientation platform 124 through relative movement between the configuration linkage 126 links along multiple setup joint (SUJ) axes. Each of the first configuration linkage 84 joint is operable to selectively orient the associated configuration linkage 100 base link with respect to the orientation platform 124 around a first SUJ axis 150, which in various embodiments is oriented vertically. Each of the configuration linkage 102 extension links can be selectively repositioned with respect to the associated configuration linkage 10 base link along a second SUJ axis 152, which is oriented horizontally in various embodiments. Each of the vertical links of configuration link 106 can be selectively repositioned with respect to the extension link of the associated configuration link 102 along a third axis SUJ 154, which is vertically oriented in various embodiments. Each of the second configuration link joints 108 is operable to selectively orient the support link of the tornado mechanism 128 with respect to the vertical link of configuration link 106 around the third axis of SUJ 154. Each of the tornado joints 132 can be operated to rotate the associated manipulator 82 around the associated tornado axis 138.

[0050] FIG. 9 illustrates the rotational orientation limits of the configuration links 126 with respect to the orientation platform 124, according to various embodiments. Each of the configuration links 126 is shown in a clockwise limit orientation with respect to the orientation platform 124. A corresponding counterclockwise limit orientation is represented by a mirror image of FIG.

9 with respect to a vertically oriented mirror plane. As illustrated, each of the two inner configuration links 126 can be oriented from 5 degrees from a vertical reference 156 in one direction to 75 degrees from the vertical reference 156 in the opposite direction. And as illustrated, each of the two outer configuration links can be oriented from 15 degrees to 95 degrees from the vertical reference 156 in a corresponding direction.

[0051] In use, it will often be desirable for a surgical assistant, surgeon, technical support, or other user to configure some or all of the links of the robotic surgery system 140 for surgery, including the configuration frame link, the configuration joints, and/or each of the manipulators. Among the tasks of configuring these links is positioning the orientation platform 124 with respect to the first-stage element 94 around the fourth vertical SUS axis 148 of the wrist joint 98. A joint drive motor 121 and/or brake system 123 is coupled to the wrist joint 98, with one exemplary embodiment including both a drive 121 and a brake 123. Additionally, a joint sensor system will typically detect an angular configuration or position of the wrist joint 98.

[0052] An exemplary user interface, system, and procedure for manually configuring the system for use is described in this invention with reference to the manual articulation of the orientation platform 124 by means of the wrist joint 98 articulation around the fourth SUS axis 148, as illustrated schematically by arrow 127. It is understood that alternative embodiments may be employed to articulate one or more alternative joints of the overall kinematic system, including one or more alternative joints of the configuration structure, one or more of the configuration joints, or one or more of the manipulator linkage joints. The use of the exemplary embodiment to articulate the motorized wrist joint embodiments may enable a user to efficiently position the manipulators 82. The manual articulation of the wrist joint 98 as described in this invention may improve speed and ease of use while manually coupling the manipulators 82 to their associated cannulas 64, as shown in FIG. 5B.

[0053] FIG. 10 shows a center of gravity diagram associated with a rotation limit of a support link for a robotic surgery system 160, according to various embodiments. With the components of the robotic surgery system 160 positioned and oriented to displace the center of gravity 162 of the robotic surgery system 160 by a maximum distance to one side with respect to a support link 164 of the surgery system 160, a shoulder joint of the support link 164 can be configured to limit the rotation of the support structure 164 about a shoulder joint axis 166 of the setup structure (SUS) to prevent exceeding a predetermined stability limit of the mounting base.

[0054] Figure 11 schematically illustrates a procedure for positioning the orientation platform 124 by articulating the wrist joint 98. As described in general above, the robotic system 140 can be used in a master tracking mode for treating tissues and the like. The robotic system will typically stop tracking and initiate 131 a setup mode that allows a user to manually set the orientation platform to a desired orientation around the fourth SUS axis 148. Once setup mode has been entered, the current angle 0<c> of the wrist joint 98, as detected by the joint sensor system, is set to the desired angle 0d in step 133. If a cannula is mounted on any of the manipulators supported by the platform 124, the system can apply the brake to the wrist joint and exit setup mode to inhibit manual movement of the wrist joint via step 135.

[0055] While in setup mode, when the platform is not moving around the wrist joint, the system processor will typically transmit signals to the joint motor associated with wrist joint 98 to maintain the set desired angle 0<d>. Therefore, when the system is bumped, pushed, or pulled slightly, the wrist motor can push the platform into the desired angle by applying a joint torque according to an error E that varies with the difference between the detected joint position and the desired joint position:

This actuation of the joint to the desired pose in stage 137 will often be limited to allow a user to overcome the wrist joint servomechanism by applying sufficient force 139 against the linkage system. For example, when the joint sensing system indicates a joint displacement beyond a threshold amount, when the torque applied to the motor to counteract the applied force reaches a threshold amount, when a detected force applied to the linkage system distal to the joint exceeds a threshold amount, or similarly, the processor may stop the wrist joint servomechanism to counteract the joint movement. In some embodiments, there may be a time element to the force threshold for overcoming the servomechanism, such as stopping the servomechanism in response to a torque exceeding a threshold for a time exceeding a threshold. Other options are still possible, including more complex relationships between threshold force or torque and time, detecting that the force is applied to a particular link or subset of links supported by the wrist (or other articulating joint), and the like. In one exemplary embodiment, a joint sensor between the orientation platform and the rest of the setup structure system provides a signal used to estimate the torque applied to the orientation platform, and the joint displacement and servo stiffness are used to estimate a perturbation torque applied to the surgical arms and/or setup joints. In a further exemplary embodiment, the error signal can be filtered to make the system more sensitive to transient impulses than to slow-state or steady-state signals. Such error filtering can make the trigger more time-sensitive, limiting false triggers when the setup structure is on an inclined surface.

[0056] When a user pushes or pulls on one or more of the surgical manipulators, the configured articulation links, or directly on the platform with sufficient force to overcome the desired articulation threshold, the user can rotate the orientation platform without having to contend with the servo control. Although the servomechanism for counteracting the user's movement of the platform stops at step 141, drive signals can still be sent to the wrist motor. For example, friction compensation, gravity compensation, momentum compensation, and/or the like can be provided 143 by applying appropriate drive signals during manual movement of the platform. Exemplary compensation drive systems are more fully described in U.S. Patent Publication 2009/0326557 to Neimeyer entitled "Friction Compensation in a Minimally Invasive Surgical Apparatus," and in U.S. Patent Publication 2011/0009880 to Prisco et al. and entitled "Control System for Reducing Internally Generated Inertial and Frictional Resistance to Manual Positioning of a Surgical Manipulator," and similar documents. In some embodiments, the system may employ a joint range-of-motion limit alone or in addition to the actuation signals when the servomechanism is stopped. Such range-of-motion limits may respond similarly to the servomechanism when a user pushes beyond a range-of-motion limit, except that they are unilateral.

[0057] Once the user has manually articulated the wrist close to the desired orientation, the user will tend to reduce the platform's speed and, upon reaching the desired setting, will stop the platform's movement. The system takes advantage of this, and as the joint sensor indicates that the platform's movement falls below a desired threshold of zero, the processor, in response, can reset the desired joint angle and restart the servomechanism (or braking) to inhibit movement from that joint position. Because the user may want to reverse the direction of the manual joint to correct any overshoot, the processor cannot re-engage the servo until the joint speed remains below a threshold for a desired dwell time.

[0058] Therefore, although the invention is susceptible to various modifications and alternative constructions, some illustrated embodiments thereof are shown in the drawings and have been described in detail above. However, it should be understood that there is no intention to limit the invention to the specific form or forms described, but rather, the intention is to cover all modifications, alternative constructions, and equivalents that fall within the scope of the invention as defined in the appended claims.

[0059] The use of the terms "a," "one," "the," and similar references in the context of describing the invention (especially in the context of the following claims) shall be construed as encompassing both the singular and the plural, unless otherwise indicated in this invention or clearly contradicted by the context. The terms "comprising," "having," "including," and "containing" shall be understood in an open sense (i.e., meaning "including, but not limited to") unless otherwise specified. The term "connected" shall be construed as partially or wholly contained within, coupled to, or joined, even if there is something intervening. The enumeration of ranges of values in this invention is intended merely as a shorthand procedure for referring individually to each separate value within the range, unless otherwise indicated in this invention, and each separate value is incorporated into the specification as if it were individually mentioned in this invention. All the procedures described in this invention can be performed in any suitable order unless otherwise stated in this invention or clearly contradicted by the context. The use of any and all examples, or exemplary language (e.g., “such as”) provided in this invention is intended merely to better explain embodiments of the invention and does not impose a limitation on the scope of the invention unless otherwise claimed. Nothing in the specification shall be construed as indicating any element not claimed as essential to the practice of the invention.

[0060] Preferred embodiments of this invention are described herein, including the best means known to the inventors for carrying out the invention. Variations from these preferred embodiments may be apparent to those skilled in the art upon reading the foregoing description. The inventors expect that those skilled in the art will employ such variations as appropriate, and the inventors do not intend the invention to be put into practice in any manner other than as specifically described herein. Accordingly, this invention includes all modifications and subject-matter equivalents mentioned in the claims presented herein to the fullest extent permitted by applicable law.

Claims (14)

1. A robotic system, comprising: a link (94) coupled to a joint (98); a drive system (121) or brake system (123) coupled to the joint (98); and a joint sensor configured to detect torques applied to the joint (98) by manual efforts of a user; a manipulator (82) coupled to the link (94); and a processor, characterized in that the processor is configured to: transmit signals to the drive system (121) or brake system (123) to inhibit the user's manual articulation of the link (94) from a first pose in response to a first manual effort by the user against the link (94) that is below a desired articulation threshold; altering the signals in response to a second manual effort by the user to articulate the link (94) that exceeds the desired articulation threshold, wherein the altered signals are configured to facilitate a manual movement of the link (94) from the first pose to a second pose by the user; and inhibit, in response to mounting a cannula on the manipulator (82), the manual articulation of the joint (98) by the user by exceeding the second manual effort to articulate the link (94) the desired articulation threshold, wherein the mounting of the cannula is determined according to the signals transmitted by the manipulator (82). 2. The robotic system according to claim 1, wherein the processor is configured to inhibit the manual articulation of the joint (98) by using the brake system (123). 3. The robotic system according to claim 1 or 2, wherein the manipulator (82) includes a cannula interface for releasably receiving the cannula. 4. The robotic system according to any of claims 1 to 3, wherein: The robotic system is a surgical robotic system; the link (124) supports a plurality of manipulators (82); and Each of the plurality of manipulators is configured to releasably receive a surgical instrument. 5. The robotic system according to claim 1, wherein the processor is further configured to: determine the second pose in response to the detection that a manual movement speed is below a first threshold speed; and transmit the signals to the drive system (121) or brake system (123) to inhibit the manual movement of the link (94) from the second position. 6. The robotic system according to claim 1 or 5, wherein the joint sensor is configured to detect a first torque of the first manual effort applied to the joint (98); and where the processor is configured to determine the signals to apply a counter-torque to the link (94) that opposes the first torque and drive the link (94) towards the first pose, the drive system (121) or brake system (123) comprising a drive system. 7. The robotic system according to claim 6, wherein: The joint sensor is configured to transmit to the processor a second pair of the second manual effort applied to the joint (98) by the user; and The processor is configured to determine if the second manual effort exceeds the desired articulation threshold using the second pair, and in response to the second manual effort exceeding the desired articulation threshold, alter the signals to decrease the counter-torque so that the first pair is sufficient to manually move the link (94). 8. The robotic system according to any of claims 1 or 5 to 7, wherein: The signals comprise actuation signals; and The processor is configured to alter the drive signals in response to the second manual effort exceeding the desired articulation threshold by adding a friction compensation component to the drive signals to mitigate linkage friction (94) for manual movement into the second pose. 9. A tangible medium that incorporates computer-readable code instructions for performing a procedure to configure a robotic system, the procedure comprising: detect, using a joint sensor, a torque applied to a joint (98) by the manual effort of a user; characterized by inhibit the manual articulation of a link (94) of the robotic system by the user from a first pose in response to a first manual effort against the link (94) by the user that is below a desired articulation threshold; in response to a second manual effort by the user to articulate the link (94) that exceeds the desired articulation threshold, facilitate a manual movement of the link (94) from the first pose to a second pose by the user; and inhibit, in response to mounting a cannula to a manipulator (82) coupled to the link (94), the manual articulation of the joint (98) by the user by exceeding the second manual effort to articulate the joint (94) the desired articulation threshold, wherein the mounting of the cannula is determined according to the signals transmitted by the manipulator (82). 10. The tangible means according to claim 9, wherein the procedure further comprises inhibiting the manual articulation of the joint (98) using a braking system (123). 11. The tangible means according to claim 9 or 10, wherein the manipulator (82) includes a cannula interface for releasably receiving the cannula. 12. The tangible medium according to any of claims 9 to 11, wherein the process further comprises: transmit signals to an actuation system (121) or brake system (123) to inhibit manual articulation of the linkage (94) from the first pose in response to the first manual effort against the linkage (94) that is below the desired articulation threshold; and altering the signals in response to the second manual effort to articulate the link (94) that exceeds the desired articulation threshold, wherein the altered signals are configured to facilitate the manual movement of the link (94) from the first pose to the second pose using a movement torque lower than the desired articulation threshold. 13. The tangible means according to claim 12, wherein the process further comprises: determining the second pose in response to the detection that a hand movement speed is below a first threshold speed; and transmit the signals to the drive system (121) or brake system (123) to inhibit the manual movement of the link (94) from the second position. 14. The tangible means according to claim 12 or 13, wherein the procedure further comprises: determining the signals to apply a counter-torque to the linkage (94) opposing a first torque of the first manual effort applied to the joint (98) and pushing the linkage (94) into the first pose, the drive system (121) or brake (123) comprising a drive system.